Author Topic: Need Supercharger Install Help -RESOLVED...AGAIN & AGAIN- (Read 17360 times)

S.P. · « **on:** March 29, 2012, 03:25:05 AM »

Hello,

I'm currently in talks with DDM Works as to how to resolve this, but would also like to ask here for advice. I've run into a issue installing the new crank pulley and overlay on my engine. There is a metal fitting and line that the overlay contacts when I try to install it on the pulley. I've circled it in the pic below.

I'm thinking the new crank is fully seated as there is a metal clank when I checked that it was pushed all the way in. The stock pulley has a beveled edge which prevents the line from contacting it, but the overlay does not.

Has anyone else that has installed this kit run into this issue or have any suggestions?

Critterman · « **Reply #1 on:** March 29, 2012, 07:45:45 AM »

I do not recall anything having to be moved or repositioned, and my car is the one that nothing fits. What is that your steering rack?

JimmyBaja · « **Reply #2 on:** March 29, 2012, 08:02:50 AM »

When I did mine I received a whole new pulley & I don't recall having an issue. I do seem to remember something about specifics about how or when to attach the additional pulley to the main one (I assume this is the overlay you're talking about) . You may have to put the main pulley on the crank shaft first (loose) then attach the overlay pulley, then insert the main bolt . Make sure the key is in place & ligned up with the keyway when you seat the pulley fully on the shaft. Be sure to torque the main bolt to 150 ft/lbs!! Dave should be able to help you out on this.

S.P. · « **Reply #3 on:** March 29, 2012, 12:45:31 PM »

Well, looking at the instructions, the pic shows the new pulley clearing the tube albeit with little room to spare. Perhaps I need to try a different angle when putting it on. Unfortunately, this is also, my daily driver so I won't be able to tear it down that far again until Saturday. Even then I have to hope it doesn't rain!

S.P. · « **Reply #4 on:** March 31, 2012, 06:05:46 PM »

Does anyone know which pulley puller I need to remove the crank pulley? It came off by hand the first time I removed it, but now it's stuck. I've used two different pullers from advance and neither seems to be correct.

1LILNDN · « **Reply #5 on:** April 01, 2012, 11:38:36 AM »

You should try tapping it with a hammer from side to side litely .If it came off by hand the 1st time its only stuck at the Keyway.

S.P. · « **Reply #6 on:** April 01, 2012, 01:50:04 PM »

I ended up needing a three jaw puller to get it off, and I was shocked at what I found:

Clearly the keyway was 180 degrees from where it should have been and ate into the pulley. Strange thing is the pulley sat flush before I tightened it down. Needless to say my stock pulley is now useless. I checked the hub as well as I could to make sure the key is still there, and from what I can tell it is. There is a tab at roughly 12:00 that I circled in the pic, I'm guessing that's the key:

I then tried to install then new pulley with similar results:

Strangely, the spots where the key is trying to engage is nowhere close to where it should be. No matter how I rotate it, the new pulley won't sit all the way up to the engine block, not even the first time I took the stock pulley off and tried. Here is a pic of how close I can get it seated:

Looking for any suggestions, ideas, advice, flames...

Sol Asylum · « **Reply #7 on:** April 01, 2012, 02:12:47 PM »

It sure doesn't look like there is much of a key on the crankshaft. With the damage that was done to the pulley I would bet the key is hosed too. I think some better pictures of the crank (yes GJ I said crank) might help determine what's going on.

S.P. · « **Reply #8 on:** April 01, 2012, 02:35:01 PM »

I'll try to see if I can get some better pics. I still have both hood and radiator in so it'll be tough.

S.P. · « **Reply #9 on:** April 01, 2012, 03:03:17 PM »

Ok. So I managed to take a short video. I'm not sure if they key is the first thing I was poking at or the second thing. If the key is the second item, then it certainly looks mangled:
<embed src="http://img535.imageshack.us/flvplayer.swf?f=Pke2" width="568" height="340" allowFullScreen="true" type="application/x-shockwave-flash"/>

If the key is indeed wrecked, any idea on how I go about replacing it?

S.P. · « **Reply #10 on:** April 01, 2012, 03:53:34 PM »

UPDATE:

Turns out the key on the hub is indeed crushed. I managed to loosen the radiator mounts and and wedge my head and a light in there to verify. Now all I need to know is how to go about replacing it...

LatinVenom · « **Reply #11 on:** April 01, 2012, 06:34:50 PM »

Since this came from DDM I would think Dave should give you all the info you need.

S.P. · « **Reply #12 on:** April 01, 2012, 07:00:59 PM »

Yeah, but they're not in the office on Sundays (reasonably so). I have no doubt they'll get back to me tomorrow. I was just wondering if anyone had experience with this in the meantime. My friend has been a great help assisting me with figuring out the problem, even let me borrow his trunk until my car gets up and running! Definitely helps to have support after a major screw up like this one.

Critterman · « **Reply #13 on:** April 01, 2012, 07:43:06 PM »

can you pull it out with a magnet?

S.P. · « **Reply #14 on:** April 02, 2012, 01:29:31 PM »

Nope, the key is really stuck in there. I've tried pliers and dikes to no avail. Dave recommended that I loosen up the timining chain and pull the gear so that i can get at it better. That's probably the route I'll have to end up taking.

elff · « **Reply #15 on:** April 02, 2012, 01:37:01 PM »

Yikes

the BFH should not be used on SC installs

Sol Asylum · « **Reply #16 on:** April 02, 2012, 01:49:55 PM »

How did he get get enough force on that pulley to to f'up the key and pulley that bad? Usually there are some tell tales to let you know something ain't right.

Remember Elff, if at first you don't succeed get a bigger hammer.

elff · « **Reply #17 on:** April 02, 2012, 05:43:52 PM »

I use that with Jeep stuff. But I try to let the pro's work on the Kappa.

Good Luck S.P. Keep us updated on your progress. The end result is going to give you a big smile, so try and grin and bear it in the meanwhile.

tazz · « **Reply #18 on:** April 02, 2012, 06:05:34 PM »

Of course none of us have ever done anything stupid and inexperienced before.

elff · « **Reply #19 on:** April 02, 2012, 06:09:46 PM »

Never
Unless you include about 35 years of my life, then yes

hammy221 · « **Reply #20 on:** April 02, 2012, 06:27:23 PM »

i had nothing moved but if i recall right i had to put it on it 2 pices main par first then bolt the extension on after and when i took it off in one pice to do the water pump i had to take out one of the power steaing lines to get it off

Sly Bob · « **Reply #21 on:** April 02, 2012, 07:06:38 PM »

Quote from: tazz on April 02, 2012, 06:05:34 PM

Of course none of us have ever done anything stupid and inexperienced before.

Don't ask...

I remember years ago trying to set the timing on an old 66 Dodge that I had. It was quite a reach to get to the points so it was easier to just take the distributor out and change the points out on the bench. Took me hours before I could get the distributor in the proper orientation so the car would run. One tooth at a time...

That's the worst story I'll admit to.

1LILNDN · « **Reply #22 on:** April 02, 2012, 07:27:41 PM »

Quote from: S.P. on April 02, 2012, 01:29:31 PM

Nope, the key is really stuck in there. I've tried pliers and dikes to no avail..

SP I had a Thunderbird with a mangled keyway. I got the smallest cole chissel I could find and took a grinder and made it a little narrower then the keyway and a small hammer . I tapped the chissel at the bottom of the K/W and it started lifting out. Should be a 1/4inch K/W

S.P. · « **Reply #23 on:** April 05, 2012, 07:42:15 PM »

UPDATE:

So in order to remove the woodruff key I needed to take off the crank timing gear. Not as simple as it sounds. First, the end of the key that had been bent over on top of the timing gear had to be cut off with a dremel. Then the valve cover, chain tensioner, and exhaust cam sprocket had to be removed to create enough slack in the timing chain. Finally, I used a puller to remove the crank timing gear and expose the rest of the woodruff key. A hammer and punch loosened it up while vice grips pulled it out (thanks for the tip 1 LIL NDN). As soon as the new parts come in I'll re-time the engine and put it all back together.

elff · « **Reply #24 on:** April 05, 2012, 08:21:22 PM »

Wow, that does not sound fun. Hang in there buddy.

News:

Author Topic: Need Supercharger Install Help -RESOLVED...AGAIN & AGAIN- (Read 17360 times)